Internal component arrangement within a housing

ABSTRACT

This application relates to securing and positioning internal components within a housing of a portable computing device. In one embodiment a cowling is utilized to retain a number of board-to-board connectors within communication slots on a printed circuit board (PCB). In another embodiment a number of insert molded retaining members are utilized to prevent outward deformation of sidewalls of the portable computing device during a drop event. In another embodiment, a C-shaped washer having diametrically opposed protrusions is utilized to adjust an alignment of an internal component.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation of International Application PCT/US14/50570, withan international filing date of Aug. 11, 2014, entitled “INTERNALCOMPONENT ARRANGEMENTS WITHIN A HOUSING”, which is incorporated hereinby reference in its entirety.

FIELD

The described embodiments relate generally to internal components ofelectronic devices. More particularly, the present embodiments relate tomethods and apparatus for positioning and securing internal componentswithin a housing that can deform.

BACKGROUND

Housings formed from materials such as plastics can provide a number ofdesign challenges when adapting them for use with an electronic devicedue to the non-rigid nature of plastic housings. During a drop event,portions of a housing can deform allowing internal components to shiftout of place, which can in some instances result in the internalcomponents being disconnected or in extreme cases being damaged as aresult. The relative ease with which a housing can deform can alsoresult in misalignment between openings in the housing and internalcomponents meant to align with the openings. For example, a userinterface such as a button or switch that is supposed to be accessiblethrough an opening can experience such a misalignment, therebyprecluding a user from being able to properly interact with the userinterface. Component misalignment and shifting are generally consideredto be unacceptable attributes for an electronic device housing and canpreclude the use of a housing susceptible to deformation when theseattributes cannot be mitigated.

SUMMARY

This paper describes various embodiments that relate to securingcomponents disposed within a housing.

In one embodiment, a portable electronic device is disclosed. Theportable electronic device includes a housing that carries a firstcomponent and a second component. The portable electronic device alsoincludes a retaining system that is independent of the housing and thatsecures a relative position of the first component with respect to thesecond component, such that a spacing between the first component andsecond component is substantially maintained when an external force isapplied to the housing. In one aspect of the embodiment, the firstcomponent is a board-to-board connector and the second component is acommunication slot electrically coupled to the board-to-board connector.The retaining system includes a cowling having an inside surface thatexerts a force upon the board-to-board connector that secures therelative position of the board-to-board connector with respect to thecommunication slot.

In another embodiment, a method for securing a board-to-board connectorwithin a communication slot on a first surface of a printed circuitboard (PCB) is disclosed. The method includes at least the followingsteps: installing a connector of a board-to-board connector within thecommunication slot of the PCB; attaching a compressible layer to a topsurface of the board-to-board connector; and pressing an inside surfaceof a cowling against the compressible layer to create a preload thatbiases the connector into the communication slot.

In another embodiment, a cowling for securing a number of board-to-boardconnectors to a PCB is disclosed. The cowling includes at least thefollowing elements: a metal substrate including a flat contact regionhaving a shape and a size in accordance with a compressible pad that isattached to an end of a board-to-board connector; and a structural ribincluding an indentation in the metal substrate. A portion of thestructural rib at least partially surrounds the flat contact region ofthe metal substrate and provides structural reinforcement for the metalsubstrate.

Other aspects and advantages of the invention will become apparent fromthe following detailed description taken in conjunction with theaccompanying drawings which illustrate, by way of example, theprinciples of the described embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIGS. 1A-1B show different views of a portable computing device;

FIGS. 1C-1F show how fastening features of a protective cover can becoupled to a housing of the portable computing device;

FIGS. 2A-2B show views of a retaining system configured to inhibitdeformation of sidewalls of the portable computing device;

FIGS. 3A-3E show various C-washer configurations that can be utilized toseat an electrical component at a desirable vertical position;

FIGS. 4A-4B show internal perspective views of a number ofboard-to-board connectors and a cowling for retaining the board-to-boardconnectors within communication slots of a printed circuit board;

FIG. 4C shows a cross-sectional side view of the electronic device whenit is partially open;

FIGS. 4D-4H show cross-sectional side views of a cowling applying aseating force against a compressible layer disposed atop one end of aboard-to-board connector;

FIG. 4I shows a top view of a cowling disposed over severalboard-to-board connectors;

FIGS. 5A-5C show how a cowling can be reinforced by welding at least oneplate to an inside surface of the cowling;

FIGS. 6A-6B show a number of embodiments relating to a standoff thatboth sets a mechanical distance between a cowling and a printed circuitboard and electrically couples the cowling and the printed circuit boardtogether;

FIGS. 7A-7F show a number of carrier tab embodiments and how a carriertab can be utilized to help align a flexible circuit with a retainingfeature within a housing;

FIGS. 8A-8C show how a button switch assembly can be positioned within ahousing;

FIGS. 9A-9C show a flange for providing a particular tactile feedbackfor a button of the portable computing device;

FIG. 10A shows a button assembly disposed on a side of the portablecomputing device;

FIGS. 10B-10C show how a set of rails for a slider switch can bearranged to provide a precise track along which the slider switch can beactuated;

FIG. 11A shows an internal arrangement of components and connectorsassociated with a camera assembly;

FIG. 11B shows an external view of a camera assembly of the portablecomputing device;

FIGS. 12A-12B show how reducing a thickness of a cut can increase a sizeof a portion of a flexible connector; and

FIG. 13 shows a block diagram representing a method for securing anumber of board-to-board connectors to a circuit board.

DETAILED DESCRIPTION

Representative applications of methods and apparatus according to thepresent application are described in this section. These examples arebeing provided solely to add context and aid in the understanding of thedescribed embodiments. It will thus be apparent to one skilled in theart that the described embodiments may be practiced without some or allof these specific details. In other instances, well known process stepshave not been described in detail in order to avoid unnecessarilyobscuring the described embodiments. Other applications are possible,such that the following examples should not be taken as limiting.

In the following detailed description, references are made to theaccompanying drawings, which form a part of the description and in whichare shown, by way of illustration, specific embodiments in accordancewith the described embodiments. Although these embodiments are describedin sufficient detail to enable one skilled in the art to practice thedescribed embodiments, it is understood that these examples are notlimiting; such that other embodiments may be used, and changes may bemade without departing from the spirit and scope of the describedembodiments.

Housings for portable computing devices often provide structuralmounting positions for various electronic components disposed within thehousing. In some cases, electronic components disposed within a housingcan move or shift from their desired positions. This is particularlytrue for a housing formed from a material that can deform; an interiorposition of electronic components disposed within the housing can changewhen the housing deforms. One way to mitigate undesirable movement ofelectronic components within a housing made from deformable materials isto add a rigid interior frame member within the housing. A rigidinterior frame member can increase the rigidity of the housing and atleast assist in maintaining a known interval between two componentsmounted to the rigid interior frame member. Unfortunately, even whencomponents are attached to the rigid interior frame member, deformationof the housing can still cause components to shift, which can inducedisconnections and/or damage to the components. A likelihood of theseproblems can be reduced in a number of ways. For example, in someembodiments a feature can be added that can prevent or inhibitdeformation of the housing and in other embodiments internal connectionscan be made more robust.

Board-to-board connectors are particularly vulnerable to disconnectionfrom a PCB to which they are attached. Board-to-board connectors aretypically used to transfer signals from one PCB to another. Aboard-to-board connector is typically a flexible cable with a connectorat each end that snaps into a communication slot on each of the PCBs,thereby establishing a robust communications channel between the twoPCBs. The board-to-board connectors can be utilized to attach a mainlogic board to other electronic components and subassemblies within theportable computing device. While in some cases board-to-board connectorsinclude a “snap and lock” feature that can help prevent the connectorsfrom detaching from the communication slots when the portable computingdevice experiences external forces (e.g., when an individual drops hisor her portable computing device onto a hard surface), the “snap andlock” feature is often inadequate for this purpose, and additionalreinforcing mechanisms are often required. One example of a reinforcingmechanism is a cowling that can be secured over the board-to-boardconnectors. The cowling can exert pressure upon at least one end of aconnector to reduce a likelihood of disconnection. In this way, thecowling imparts a force against the connector that assists in retainingthe connector within a communication slot. In some cases, a compressiblelayer along the lines of a foam pad can be disposed between the cowlingand the connector to increase tolerances between the cowling andconnector. Implementation of the compressible layer can be particularlybeneficial when the cowling is subjected to bending forces during, forexample, a drop event. In some embodiments, a shape and/or a thicknessof various portions of the cowling can be optimized to preventdeformation of the cowling, thereby preventing situations in which thecowling pulls away from the connector. In some embodiments, the cowlingcan be selectively thickened while in other embodiments the cowling caninclude a number of structural rib features to increase an overallrigidity of the cowling.

In some embodiments, the aforementioned cowling can be separated fromthe PCB by a standoff. The standoff can be configured to provide apathway through which a fastener can affix both the cowling and the PCBto an internal surface of the housing. In addition to providing a fixedstandoff distance between the cowling and the PCB, the standoff canprovide an electrically conductive pathway through which the cowling andPCB can be electrically coupled, thereby facilitating grounding of thePCB through at least a portion of the cowling.

In some embodiments, a board-to-board connector secured by the cowlingcan be coupled with more than one component. By splitting one end of theboard-to-board connector into two portions or “tails,” the tails canflex to attach to the different components. When maintaining a size ofthe tails is important, any waste of a portion of the flexible circuitcan be highly undesirable. In such a case, minimizing an amount ofmaterial removed when splitting the tails is of great importance. Insome embodiments, a small diameter laser cutter can be used to separatethe tails, leaving only a small gap between the tails, on the order ofabout 0.025 mm, thereby increasing an effective surface area of thetails.

In some embodiments, an alignment system can be utilized to preventundue shearing forces upon a button assembly. A switch associated with abutton assembly can include a protrusion that fits in an opening of abracket. The protrusion and opening in the bracket cooperate to anchorthe switch and to prevent shearing forces from compromising a couplingbetween the switch and the bracket. The interaction between theprotrusion and the opening also helps facilitate alignment of the switchwith the bracket.

In some embodiments, a flange can be positioned to create a seal betweena button disposed within an opening and a protective cover defining theopening. A thickness of the flange can be increased to prevent damagebeing inflicted upon the flange during repeated actuation of the button.In this particular embodiment, the flange is selectively thickened sothat strengthened/thickened areas of the flange do not impinge uponareas of the portable electronic device that include other components.

In some embodiments, a rail system made up of a number of rails can bemounted directly to the interior frame member associated with thehousing. The rails define a path of movement for a slide switch. In thisway, the interior frame helps to define a fixed distance between therails, thereby preventing binding of the slide switch within the rails,as might be the case for a rail system that was coupled directly to adeformable portion of the housing. Positioning of the rail system indirect contact with the internal frame member also prevents the railsfrom shifting in the event of an associated sidewall of the housingdeforming.

In some embodiments, a sidewall of the housing includes a fasteneropening for securing a protective cover that overlays a display assemblyof the portable computing device to the housing. A metal plate can beutilized to guide the fastener through an opening in an insert moldedcomponent disposed between the fastener opening and a fastening feature(sometimes referred to as a fang) extending from the display assembly.The metal plate can be positioned within the housing by adhesivelycoupling it to the insert molded part positioned proximate the fasteneropening. In situations where an opening in the metal plate and thefastener opening are not well aligned, or where the housing shiftssubstantially with respect to the metal plate, the fastener canexperience undesirable shearing forces or in some instances be unable tocouple with the fastening feature of the display assembly. By adheringthe metal plate to the insert molded part with low shear adhesive, themetal plate can shift with respect to the insert molded part to allowthe fastener to engage the fastening feature during an assemblyoperation.

In some embodiments, flexible sidewall portions of a housing can bereinforced by a number of retaining members (in some instances referredto as retaining knuckles). The retaining members can be disposed withinthe housing as follows. A retaining member that defines a retainingchannel can be insert molded along an inside surface of a sidewall ofthe housing. A protrusion having a size and shape in accordance with theretaining channel can be formed along an inside surface of a rigidprotective cover that overlays a display assembly. When the protectivecover is mated with the housing, the protrusion is seated within theretaining channel so that the protrusion is operable to preventdeformation of the sidewall by interacting with the retaining membersdefining the retaining channel.

In some embodiments, a C-washer can be used to provide precise verticalalignment of a docking connector with an opening in a housing. TheC-washer can be a C-shaped plate having an interior diameter andexterior diameter. In some embodiments the C-washer can have a curvaturethat causes one pair of diametrically opposing high points disposedaround the interior diameter of the C-washer to be oriented in a firstdirection and another pair of diametrically opposing high points to beoriented in a second direction opposite the first direction. Thediametrically opposing high points enable the C-washer to make evencontact with objects disposed both above and below it. In someembodiments, the C-washer can have four, six or even eight high points.The C-washer can be formed of any number of electrically conductivematerials such as for example, spring steel, beryllium copper, andtitanium copper.

In some embodiments, a carrier tab can be utilized to align a componentwithin a portion of the portable computing device. The carrier tab caninclude one or more breakaway holes that facilitate removal of abreakaway portion of the carrier tab. In this way, a robotic arm orsimilar holding apparatus that can be a part of a computer aidedmanufacturing system can hold the breakaway portion of the carrier tabwhile the remainder of the carrier tab is coupled with an interiorsurface of the portable computing device and the component. Subsequentto installing the carrier tab, the breakaway portion can be removed. Insome embodiments, the carrier tab can be operative to secure one end ofa flexible circuit within the portable computing device.

These and other embodiments are discussed below with reference to FIGS.1A-13; however, those skilled in the art will readily appreciate thatthe detailed description given herein with respect to these figures isfor explanatory purposes only and should not be construed as limiting.

FIGS. 1A and 1B show different views of portable computing device 100.FIG. 1A shows a perspective view of portable computing device 100 andFIG. 1B shows a top view of portable computing device 100. Althoughembodiments herein depict portable computing device 100 taking the formof a mobile phone, this is for illustrative purposes only and it shouldbe appreciated that portable computing device 100 can take the form ofother devices. By way of non-limiting example, portable computing device100 can also be embodied as a tablet computing device, a user interfacedevice, a media player, and/or any other electronic device that caninclude a flexible housing enclosure.

Portable computing device 100 can include protective cover 102 andhousing 104. Housing 104 can include a number of walls, including abottom wall and a number of sidewalls, which cooperate to define acavity for housing internal components of portable computing device 100.Housing 104 can be made at least in part from materials that haveelastic deformation properties. In this regard, portions of housing 104can temporarily deform when a force is exerted upon housing 104 andreturn to its original shape after the force is removed. For example, aportion of housing 104 can deform by compression, expansion, bowing,and/or flexing. Housing 104 can be made from polymers such as plasticthat can have a high elastic limit. In one embodiment, housing 104 isformed from a unitary piece of plastic. Portions of housing 104 can varyin thickness and rigidity. In this regard, some portions of housing 104can be substantially rigid while other portions can be more flexible.

A front opening of the cavity defined by a top inside edge of thesidewalls of housing 104 can receive protective cover 102. For example,protective cover 102 can be received and coupled to housing 104 byfriction fitting, one or more fastening systems, and/or a combinationthereof. In this regard, when assembled, housing 104 and protectivecover 102 cooperate to enclose components of portable computing device100. In some embodiments, an enclosed component can be used to assist inthe alignment and positioning of other components of portable computingdevice 100. In one specific embodiment, portable computing device 100can include an interior frame member (not depicted) that helps toreinforce housing 104 and to provide a rigid structure upon which othercomponents can be mounted. In this way, spacing between internalcomponents mounted with the rigid frame member can be improved.

In some embodiments, a component can be a user interface that provides auser of portable computing device 100 with input/output (I/O)functionality. For example, protective cover 102 can include displayassembly system 103 disposed between protective cover 102 that providesa touch-screen driven user interface. Portable computing device 100 canalso include one or more tactile interfaces such as button assembly 105a and button assembly 105 b that can be disposed on the sides ofportable computing device 100. Portable computing device 100 can alsoinclude one or more audio interfaces such as headphone jack opening 106,microphone opening 107 and a number of speaker openings 108 a that canbe disposed along one of the sidewalls of housing 104. Another speakeropening 108 b can be disposed along a top surface of protective cover102. Furthermore, portable computing device 100 can include a dataconnector having an exterior opening defined by trim ring 110 that isalso disposed along one of the sidewalls of housing 104.

FIGS. 1C-1F show a number of views of a bottom portion of portablecomputing device 100. FIG. 1C in particular shows an external view of asidewall of housing 104 of portable computing device 100. Protectivecover 102 that overlays display assembly system 103 is joined to housing104 at least in part by fasteners 112. Fasteners 112 can be electricallyconductive metal fasteners formed from any number of materials,including for example stainless steel, carbon steel, aluminum, copper,brass or phosphorous bronze. In some embodiments, protective cover 102can be formed from a layer of high strength glass, sapphire or otherhigh strength transparent material. Fasteners 112 pass through openingsin housing 104 to engage fastening features (not depicted in FIG. 1C)extending from an inside surface of protective cover 102, therebysecuring protective cover 102 to housing 104. A data connector openingis also depicted, the data connector opening being defined by trim ring110. When a portion of housing 104 surrounding the data connectoropening is flexible, trim ring 110 can be formed from a rigid materialthat reinforces the opening and prevents deformation of the openingleading into the data connector. In this way, trim ring 110 can providean opening through the flexible portion of housing 104 that operates tomaintain a size and shape of the opening in accordance with a dataconnector plug that engages a data connector assembly disposed withinhousing 104. FIG. 1C also depicts headphone jack opening 106, microphoneopening 107 and speaker openings 108 a.

FIG. 1D shows a partial cross-sectional view of portable computingdevice 100 in accordance with section line A-A as depicted in FIG. 1C.Fasteners 112 are disposed through fastener openings in housing 104.Fasteners 112 also pass through openings in reinforcement plates 114which are adhesively coupled with insert molded part 116. Reinforcementplates 114 help to guide fasteners 112 through insert molded part 116and towards fastening features 118 (in some cases referred to asprotective cover fangs). In some embodiments, fasteners 112 can beutilized to form openings in insert molded part 116 during initialassembly of portable computing device 100. Without the alignmentprovided by reinforcement plates 114, formation of the opening duringinitial assembly can cause portions of insert molded part 116 to bedestroyed in instances where fasteners 112 are driven through insertmolded part 116 at an incorrect angle. The adhesive coupling betweeninsert molded part 116 and reinforcement plates 114 can be formed by alow shear adhesive that allows reinforcement plates 114 to shiftslightly with respect to insert molded part 116 while fasteners 112 areengaging fastening features 118. This ability of reinforcement plates114 to shift prevents reinforcement plates 114 from preventing precisealignment of fasteners 112 with fastening features 118 in cases ofslight misalignment of reinforcement plates 114 due to sample variationin component parts and/or tolerances inherent to the assembly process.

Reinforcement plates 114 can be formed from any high strength materialsuch as, for example, stainless steel or carbon steel. Fasteners 112engage with openings in fastening features 118 to secure protectivecover 102 to housing 104. Fastening features 118 can be metalprotrusions having threaded openings configured to retain fasteners 112.Insert molded part 116 can be formed of an insulating material such asplastic or foam that electrically isolates reinforcement plates 114,fasteners 112 and fastening features 118 from trim ring 110. This can beof particular importance when a data connector plug is engaged withintrim ring 110, thereby grounding trim ring 110 through the dataconnector plug. This grounding can cause electromagnetic interference tobe generated at trim ring 110, which can in turn affect sensitivecomponents such as antennas proximate to trim ring 110. By insulatingthe aforementioned components from trim ring 110, these additionalelectrically conductive components can be prevented from also beinggrounded to the data connector plug through trim ring 110, therebyminimizing an amount of electromagnetic interference generated by theelectrical coupling between the data connector plug and trim ring 110.

FIG. 1E shows a partial cross-sectional side view of portable computingdevice 100 in accordance with section line B-B as depicted in FIG. 1C.Fastening features 118 are joined with and extend from a bottom surfaceof protective cover 102 and into an interior portion of housing 104.Fastening features 118 can be electrically conductive and are joined toprotective cover 102 by a sealing member 120 that is electricallyinsulating. Sealing member 120 can be formed from materials along thelines of plastic or rubber. Protective cover 102 is also generallyformed of insulating material along the lines of glass or sapphire,which can also prevent electrical coupling between electrical componentsassociated with protective cover 102 and fastening features 118.Positioning of fastening features 118 in this manner allows fasteningfeatures 118 to be aligned with fastener openings in housing 104 withoutbeing electrically coupled to electrical components associated withprotective cover 102. Fastener 112 is depicted passing through afastener opening in housing 104 and an opening in fastening feature 118,thereby coupling protective cover 102 to housing 104. Electricallyconductive pathway 122 depicts a potential flow of electrical energythrough fastener 112, reinforcement plate 114 and fastening feature 118.As can be seen, insert molded part 116, housing 104 and sealing member120 effectively insulate these components so that if fastener 112receives an electrostatic discharge the electrical energy is notpropagated to electrically sensitive components. Furthermore, theinsulating components prevent these electrically conductive elementsfrom being included in a grounding path through the trim ring (shown inFIG. 1D). This can be particularly beneficial in this embodiment, giventhe short distance between fastening feature 118 and antenna 124. FIG.1F shows an internal, cross-sectional view of the bottom portion ofportable computing device 100. In this view, a shape and size of insertmolded part 116 is depicted in relation to trim ring 110. FIG. 1Fdepicts separation between trim ring 110 and reinforcement plates 114.Additionally, fastening features 118 are depicted extending above insertmolded part 116.

FIGS. 2A-2B show how a retaining system can be utilized to inhibitsidewalls of housing 104 from bowing outwards and away from protectivecover 102 when an external force is received at housing 104. A dropevent can impart a force on housing 104 that causes sidewalls 200 a, 200b of housing 104 to bow outwards, particularly when portable computingdevice 100 is dropped on a corner, e.g., corner regions 200 c/200 d, ofhousing 104. The impact from dropping portable computing device 100 on acorner can result in a propagation of the force from the drop to atleast one of sidewalls 200 a and 200 b, causing at least one ofsidewalls 200 a,200 b to deform. Deformation of sidewalls 200 a,200 bcan result in outward bowing of the sidewalls. Outward bowing of asidewall can increase the volume of housing 104, allowing internalcomponents to shift during a drop event, which can in many cases causedamage or compromise the functionality of the internal components. Forexample, outward bowing can cause components associated with headphonejack opening 106, microphone opening 107 and speaker openings 108 a toshift thereby causing a misalignment with their corresponding openings.Misalignment with the corresponding opening can compromise thefunctionality of the component. Shifting of internal components can alsocause disconnection of interior components, thereby disabling thedisconnected interior components.

FIG. 2A shows how protrusions 202 and 204 can extend from a bottomsurface of protective cover 102. The protrusions can take on differentshapes. In some cases, as depicted, protrusion 202 can include astrengthening feature 206 that increases a lateral rigidity ofprotrusion 202. For example, strengthening feature 206 can have a closedshaped disposed at one end of protrusion 202 that reinforces protrusion202. In other cases, as depicted, protrusion 204 can have a more linearshape to fit between other components disposed within housing 104.Protrusions 202 and 204 can each have portions that are substantiallyparallel with portions of cover component 102. For example, a linearportion of protrusion 202 can be substantially parallel with an edge ofcover component 102, and a curved portion of protrusion 204 can besubstantially parallel with a corner portion of cover component 102.Portions of the protrusions can also be substantially parallel withportions of housing 104. For example, a portion of protrusion 202 can besubstantially parallel with sidewall 200 a. In some embodiments,protrusions 202 and/or 204 can be coupled to protective cover 102 withan adhesive. In other embodiments, protrusions 202 and/or 204 can becoupled to protective cover 102 with a fastening system along the linesof a screw and threaded opening.

As protective cover 102 mates with housing 104, protrusions 202 and 204cooperate with corresponding retaining members disposed in housing 104to reinforce sidewalls 200 a, 200 b. It should be noted that FIG. 2Adepicts protective cover 102 having protrusions disposed in only twocorners; however, in other embodiments protrusions and correspondingretaining members can be disposed at other locations within portablecomputing device 100. For example, protrusions and retaining members canbe disposed in each of the corners of housing 104. In another example,protrusions and retaining members can cooperate to reinforce otherportions of a sidewall such as a central portion of sidewalls 200 a, 200b and/or the sidewall between corner portions 200 c and 200 d. In yetanother example, a protrusion and a retaining member can be disposed ata central portion of the portable computing device 100. Furthermore, aprotrusion can be retained by more than one retaining member. Forexample, a first portion of a protrusion can be retained by a retainingmember at one corner while a second portion of the protrusion can beretained by another retaining member disposed at another corner.Similarly, a retaining member can retain more than one protrusion. Forexample, a retaining member can define two or more channels forretaining more than one protrusion. Any number of protrusions andretaining member can be used. It is particularly useful to positionprotrusions and retaining members along portions of housing 104 that arelikely to deform during a drop event.

FIG. 2B shows a partial cross-sectional view of portable computingdevice 100 when protective cover 102 is mated with housing 104. Aportion of protrusion 202 is disposed within a channel formed byretaining member 208. The channel formed by retaining member 208 canhave a shape that is complementary to a portion of protrusion 202,allowing the channel to surround a portion of protrusion 202. In thisway, protrusion 202 can restrict movement of retaining member 208 whensidewall 200 a is deformed. Similarly, protrusion 204 can restrictmovement of retaining member 210 when sidewall 200 b is deformed.Retaining members 208 and 210 can be integrally formed with housing 104.For example, retaining members 208 and 210 can be formed along an insidesurface of housing 104 using insert molding techniques. In someembodiments, both retaining members 208, 210 and protrusions 202,204 canbe formed from rigid material along the lines of glass filled nylon. Insome embodiments, retaining members 208 and 210 can be reinforced inpart by reinforcement features 212 a and 212 b respectively.Reinforcement features 212 a,212 b can be, for example, at least aportion of a rigid interior frame member disposed within housing 104.The rigid interior frame member can be particularly effective atpreventing inward deformation of housing 104 when housing 104 issubjected to an external force.

Protrusion 202 cooperates with retaining member 208 to preventsubstantial movement of sidewall 200 a when subjected to an externalforce F. In this embodiment, retaining members 208 and 210 are disposedwithin corner regions 200 c and 200 d respectively. As previouslydiscussed, dropping portable computing device 100 on a corner can cause,for example, corner region 200 c to be compressed. Without the benefitof retaining member 208, the compression at corner region 200 c can betransmitted along sidewall 200 a, potentially causing damage or shiftingof components disposed proximate to sidewall 200 a. By positioning theretaining members 208 and 210 at the corner regions 200 c and 200 drespectively, a force exerted on a corner can be mitigated or absorbedby retaining members 208 and 210, thereby preventing energy impartedduring the drop from propagating to sidewalls 200 a and 200 b. In thisway, the retaining members can prevent substantial deformation ofsidewalls 200 a and 200 b when portable computing device 100 is exposedto an external force. It should be noted that this configuration isparticularly effective when protective cover 102 is formed from amaterial that is more rigid than materials used to form housing 104. Forexample, when protective cover 102 is formed from a rigid material suchas glass which is unlikely to substantially deform during a drop event,protective cover 102 can keep protrusions 202 and 204 firmly in place,thereby preventing retaining members 208 and 210 and the attachedsidewalls from deforming. It should be noted that glass is generallyknown to be particularly robust in tension, making it an excellentanchor for protrusions 202 and 204 during a drop event.

FIGS. 3A-3B show a C-washer 300. C-washer 300 can be a disc-shaped platehaving a front opening 302 and center opening 304. C-washer 300 can bemade from conductive materials such as steel, cooper, or conductiveplastic. In this regard, C-washer 300 can provide an electrical path forobjects that are contacting C-washer 300. For example, C-washer 300 canbe used to ground components that contact C-washer 300. In otherembodiments, C-washer can be made from non-conductive materials.

Front opening 302 allows C-washer 300 to be deformed so that centeropening 304 is temporarily expanded so that C-washer 300 can surround anobject. For example, C-washer 300 can surround a fastening device suchas a screw, nut, or boss. To receive these objects, C-washer 300 can beopened by applying a force that increases a size of center opening 304so that it is large enough to surround an object. When the object isreceived and the deforming force is removed, the C-washer 300 can “snap”back into its original shape thereby causing interior protrusions 306 toexert a force upon a peripheral surface of the object that keeps theC-washer firmly in place around the object. The elastic properties thatallow C-washer to open and return back to its original shape can beprovided by the materials used to form C-washer 300. In this regard,unlike traditional washers, C-washer 300 retains itself to an object,thereby decreasing the likelihood of C-washer 300 being inadvertentlyremoved from the object it retains. This feature is particularly usefulduring an assembly process when movement and rotation of components cancause C-washer 300 to fall off the object. Center opening 304 can bedefined by an interior surface of C-washer 300 that includes a number ofinterior protrusions 306. Protrusions 306 can be diametrically opposedso that when C-washer 300 is compressed by a surface of a component,protrusions 306 self-level so that force exerted by the component on theC-washer is evenly distributed. Also depicted is how one pair ofprotrusions point in one direction while the other set of protrusionspoint in another direction by virtue of an overall curvature of C-washer300.

FIG. 3B shows an exemplary use of a number of C-washers 300. C-washers300 are depicted as being retained around bosses 308 a which aredisposed along an interior surface 310. Bosses 308 b are disposed alonginterior surface 312 that is positioned above interior surface 310. Inthis regard, bosses 308 b are disposed above bosses 308 a. During anassembly operation, a component such as a data connector assembly (notshown) can be installed using bosses 308 a and 308 b. When assembled,the data connector is aligned with opening 314 and engaged with bosses308 a and bosses 308 b. Furthermore, the data connector assembly canalso be secured to a sidewall of the housing by a fastener that isdriven through openings 316 and an attachment feature associated withthe data connector assembly.

Because C-washers 300 are configured to deform, an amount of engagementbetween C-washers 300 and the data connector assembly can be adjusted ortuned during an assembly operation. A position of an opening of the dataconnector assembly can be changed by adjusting the amount of engagementbetween the C-washers and the data connector assembly so that an openingin the data connector assembly aligns with opening 314. Furthermore,this type of adjustment can help to align fastening features of the dataconnector assembly with openings 316. In some embodiments, it may bedesirable to reduce an amount of compression applied to C-washers 300 toincrease a height at which the data connector assembly engages bosses308 a so that the data connector assembly engages bosses 308 a and 308 bwithin the same vertical plane. In this regard, C-washers 300 can alsobe especially helpful when component-to-housing tolerances are such thata slight vertical height adjustment may be necessary. In someconfigurations, bosses 308 a can include a lip that engages withprotrusions 306. In this way, the lip can help to keep C-washers 300from sliding off of bosses 308 a. In other configurations, protrusions306 can engage an outside surface of bosses 308 a to maintain C-washers300 in place during assembly, obviating the need for a lip feature onbosses 308 a.

FIGS. 3C-3E show top views of a number of alternative configurations inwhich the C-washers can be formed. FIG. 3C shows a top view of C-washer300 of FIG. 3A. C-washer 300 includes two sets of diametrically opposedprotrusions 306 that face one another. FIG. 3D shows a top view ofC-washer 320 with three sets of diametrically opposed protrusions 322facing one another. FIG. 3E shows a top view of C-washer 340 with foursets of diametrically opposed protrusions 342 facing one another.

FIGS. 4A-4B show internal perspective views of an interior portion ofportable computing device 100. FIG. 4A shows a main logic board (MLB)402 configured to support a number of electronic components such asintegrated circuits along the lines of central processing units (CPU)and graphics processing units (GPU). MLB 402 can be electrically coupledto other subassemblies and printed circuit boards disposed in variouspositions within portable computing device 100 by a number ofboard-to-board connectors. For example, board-to-board connector 404 isdepicted mating with a communication slot disposed on MLB 402.Compressible layer 406 is disposed atop board-to-board connector 404. Insome embodiments, compressible layer 406 can be formed of conductivefoam. When a retaining member, such as a cowling, compressescompressible layer 406 a preload is established between the retainingmember and compressible layer 406. In one embodiment, the opposite endof board-to-board connector 404 can electrically couple MLB 402 withdisplay assembly 103. Similarly, board-to-board connector 408 can coupleMLB 402 to a camera module disposed within camera module cowling 410.Similar to board-to-board connector 404, board-to-board connector 408can also have a compressible layer 412 disposed over the end that iselectrically coupled with MLB 402. Board-to-board connector 414 can beconfigured to electrically couple MLB 402 with other components such asbutton assemblies and sensors. In some embodiments, board-to-boardconnector 414 associated with compressible layer 416 can pass underneatha battery assembly (not shown) to couple with various other componentsdisposed within portable computing device 100. It should be noted thatother connectors are also depicted and are associated with compressiblelayers 418 and 420. It should be noted that MLB 402 could also includevarious mounting points such as, for example, opening 421 for receivingother components or shielding elements.

FIG. 4B shows a cowling 422 disposed atop MLB 402 of FIG. 4A. Cowling422 can be secured atop MLB 402 with a number of fasteners 423. In someembodiments, fasteners 423 can be threaded screws that are securedwithin threaded openings. As depicted, cowling 422 is fastened to MLB402 in a number of different positions so that it is securely positionedwith respect to MLB 402. Cowling 422 can be a metal substrate having oneor more substantially flat regions. In one embodiment, cowling 422 canbe formed from a piece of sheet metal having a thickness of less than0.5 mm. In another embodiment, cowling 422 can have a thickness of about0.3 mm. Cowling 422 can be formed from metals including, but not limitedto, stainless steel and aluminum.

Once cowling 422 is positioned it can assist in holding the variousboard-to-board connectors depicted in FIG. 4A against communicationslots of MLB 402. In some embodiments, a flat region of cowling 422 canexert a force on a board-to-board connector through a compressiblelayer, thereby holding the board-to-board connector against acommunication slot. The flat region can have a shape and size inaccordance the compressible layer (e.g., compressible layer 412). Inthis regard, compressible layers are compressed between cowling 422 anda corresponding board-to-board connector when the cowling 422 is securedto MLB 402. As discussed in further detail below, non-flat regions ofcowling 422 can also exert a force on board-to-board connectors. In someembodiments cowling 422 can also be operative to form a faraday cagethat shields various components disposed beneath it from othercomponents disposed within portable computing device 100. Unfortunately,cowling 422 can be subject to deformation during a drop event.Deformation of cowling 422 can reduce its effectiveness as a retainingmember for the board-to-board connectors.

To reduce the severity of the deformities, cowling 422 can also includevarious reinforcing features, such as folded end portion 424. Folded endportion 424 can substantially strengthen one end of cowling 422 makingdeformation of the end on which it is disposed much less prone todeformation during a drop event. Furthermore, structural ribs 426 and428 can be formed along cowling 422 by a machining operation such asstamping to provide improved rigidity to cowling 422. The stampingoperation itself can increase rigidity of cowling 422 as it is operativeas a cold working operation. In the depicted embodiment, structural rib426 contacts a top surface of compressible layer 406, while structuralrib 428 lies just outside of a top surface of compressible layer 412. Inthis regard, structural rib 428 surrounds two sides of compressiblelayer 412 and partially surrounds a portion of an end of board-to-boardconnector 408. When structural rib 428 is disposed outside of an areataken up by compressible layer 412, then compressible layer 412 can besubstantially thicker. This is one reason why compressible layer 412 isdepicted as being thicker than compressible layer 406, since a portionof cowling 422 disposed above compressible layer 412 has a lower heightdue to structural rib 426. In one embodiment, structural ribs can beplaced in locations along cowling 422 in accordance with a heat mapgenerated by finite element analysis. While substantially linearstructural ribs are depicted, almost any shape is possible. The heat mapcan help identify portions of the cowling that undergo higher levels ofstress. In this way, ideal locations for the structural ribs can beidentified, thereby minimizing a number of ribs required to stiffencowling 422. It should also be noted that while each of the structuralribs extends towards MLB 402, in some embodiments the structural ribscan extend upwards and away from MLB 402 when space is available.

FIG. 4C shows a cross-sectional side view of portable computing device100 when partially open in accordance with one embodiment. In thisregard, protective cover 102 is tilted at an angle with respect tohousing 104. This angular positioning of protective cover 102 can beappropriate for assembling protective cover 102 with housing 104.Board-to-board connector 404 includes connector 405 a at one end andconnector 405 b at another end. Connector 405 a can be coupled to acommunication slot disposed on MLB 402. Cowling 422 and compressivelayer 406 are disposed over a portion of connector 405 a. A portion ofboard-to-board connector 404 is flexed upward such that connector 405 bcan be positioned and coupled to a communication slot disposed ondisplay assembly 103. In this regard, board-to-board connector 404electrically couples MLB 402 and display assembly 103.

As previously discussed, cowling 422 can be used to assist in theretention of board-to-board connectors. In this embodiment, cowling 422(partially depicted in FIG. 4C) can retain board-to-board connector 404to assist in keeping connector 405 a connected to the communication slotdisposed on MLB 402. In some cases, a drop event can cause connector 405a to disconnect from MLB 402. For example, a drop event can causeprotective cover 102 to separate from housing 104, which in turn pullsconnector 405 a from the communication slot disposed on MLB 402. Inanother example, a drop event can cause the sidewalls of housing 104 tobow outwards, allowing MLB 402 to shift from its original position whichcan cause disconnection. Accordingly, when cowling 422 retainsboard-to-board connector 404, particularly at connector 405 a, cowling422 can prevent disconnection of connector 405 a from MLB 402 during adrop event.

FIGS. 4D-4H show cross-sectional side views of various configurations inwhich foam layers are depicted interacting with cowling 422 to secure aboard-to-board connector against MLB 402. FIG. 4D shows across-sectional side view of connector 430 of board-to-board connector414. Similar to connector 405 a, connector 430 electrically couplesboard-to-board connector 414 with communication slot 432 disposed on MLB402. Communication slot 432 can in turn be in electrical contract withelectrical traces disposed on a top or bottom surface of MLB 402. FIG.4D also depicts how cowling 422 transmits a force through compressiblelayer 416 that helps maintain board connector 414 within communicationslot 432 of MLB 402. Because compressible layer 416 is distributedevenly on either side of connector 430, no adverse lateral forces aretransmitted when cowling 422 exerts a substantially even or at leastsymmetric force profile upon compressible layer 416. Consequently, anystructural ribs exerting force on a compressible layer should besubstantially centered with regards to connector 430 and communicationslot 432.

FIG. 4E depicts board-to-board connector 404 in accordance with sectionline D-D of FIG. 4B. Structural rib 426 is depicted having about thesame width as compressible layer 406. This allows cowling 422 to place asubstantially uniform amount of force upon compressible layer 406. FIG.4F depicts an alternative configuration of board-to-board connector 404in which two structural ribs contact compressible layer 406. Even thougheach one of structural ribs 426 is not centered with respect tocompressible layer 406, they cooperate to exert a symmetric force uponconnector 430 by way of compressible layer 406. In this way, as in theprevious examples, no substantial lateral forces are exerted. FIG. 4Gshows another similar configuration in which the depicted structural ribis substantially wider than the compressible layer; however, since thestructural rib is centered over the compressible layer, thisconfiguration would also work to secure connector 430. Finally, FIG. 4Hshows a configuration in which connector 430 of board-to-board connector408 is secured to communication slot 432 by a portion of cowling 422that is adjacent to structural rib 428. Structural rib 428 is disposednear a peripheral portion of compressible layer 412 and is not directlyabove compressible layer 412, connector 430 and/or communication slot732. In this way, structural rib 428 can surround a perimeter portion ofcompressible layer 412, connector 430 and/or communication slot 732respectively. Furthermore, structural rib 428 can define in part a flatcontact region of cowling 422 that is disposed directly overcompressible layer 412. This configuration is also desirable as the lackof a structural rib allows a relatively thicker compressible layer 412to be utilized and in some embodiments can be configured to account fora substantially larger deformation of cowling 422 than other thinnertype compressible layers. When cowling 422 deforms, the aforementionedcompressible layers are operable to maintain a force upon acorresponding board-to-board connector. In this way, a number ofundesirable board-to-board connector disconnections can be substantiallyreduced.

FIG. 4I shows a top view of an exemplary cowling 422 in accordance withsome embodiments. Cowling 422 is disposed over board-to-board connectors440/442/444. As previously discussed, structural ribs can be disposed inlocations along cowling 422 in accordance with a heat map that can helpto identify locations of cowling 422 that undergo higher levels ofstress/deformation. In this embodiment, structural ribs 446/448/450 aredisposed in various locations along cowling 422. Structural rib 446“snakes” between board-to-board connectors 440 and 442 and is notdisposed directly over any board-to-board connector. Structural ribs 448and 450 are disposed directly over board-to-board connector 514 in across pattern. In this regard, a portion of structural rib 518 isdisposed along a width of board-to-board connector 514 while a portionof structural rib 520 is disposed along a length of board-to-boardconnector 514.

FIGS. 5A-5C show an alternative way of stiffening a cowling. This can beuseful where a stamped rib does not provide a sufficient amount ofrigidity to prevent dislodgement of an underlying board-to-boardconnector during a drop event. Furthermore, in some embodiments thecowling is only a 0.3 mm thick piece of steel sheet metal that oftenundergoes deformation when exposed to high forces or loading events.Simply increasing a thickness of the entire cowling may not be feasibleas it can cause cowling 422 to interfere with other components withinportable computing device 100. For example, as depicted in FIGS. 5A and5B, a top portion of fastener 502 does not extend above a top surface ofcowling 422; however if an overall thickness of cowling 422 wereincreased it would increase a thickness of the portion of cowling 422disposed underneath fastener 502 thereby increasing an overall heightdimension of fastener 502, which in some designs could cause fastener502 to contend for space taken up by adjacent internal componentsdisposed above fastener 502. FIGS. 5A and 5B also show how metal plates504 and 506 can be welded with a bottom surface of cowling 422. In thisway a thickness of cowling 422 can be selectively tuned to add materialonly where needed. In some cases metal plates 504 and 506 can beconstructed from different material than the material that forms cowling422. The selected materials can help tune a stiffness of cowling 422 inthat particular location. The thickness of the plate or plates utilizedcan vary depending on a desired preload to be established between thewelded plates and the underlying connector. The plates are operative toset a desired distance between a bottom surface of cowling 422 andboard-to-board connector 508. FIG. 5C shows a cross-sectional side viewin which only a single metal plate 504 is welded to the bottom surfaceof cowling 422. This can be a beneficial configuration when only a minoramount of strengthening is required and/or when a distance betweencowling 422 and a top surface of the underlying connector isparticularly small. Furthermore, in certain cases single metal plate 504can be sized to have a thickness in accordance with the gap betweencowling 422 and the underlying connector.

FIG. 6A shows another interior perspective view along the lines of thedepiction of FIG. 4A. The primary difference being that theboard-to-board connector associated with compressible layer 420 has beenremoved and the corresponding communication slot 602 associated withthat connector is exposed. Communication slot 602 can include a numberof electrical contacts 602 a that cooperate with a plug of aboard-to-board connector to electrically couple MLB 402 to othercomponents. The tight spacing of electrical contacts 602 a make properalignment of the board-to-board connector with the communication slot602 particularly important. It should also be noted that standoff 604can be conductively mounted to MLB 402 and that at least a portion ofstandoff 604 can be conductive so that electricity is able to flow fromMLB 402 and through standoff 604, thereby allowing cowling 422 to beelectrically coupled to MLB 402. In one embodiment, standoff 604 can bewelded to MLB 402 prior to installation of MLB 402 within housing 104.Standoff 604 includes a top surface that can support a portion ofcowling 422.

FIG. 6B is a cross-sectional side view showing how multiple componentscan be secured using a single fastener. Fastener 606 is driven throughan opening in cowling 422 and an opening in standoff 604 to engage anopening in rigid frame member 608, thereby securing both cowling 422 andMLB 402 to rigid frame member 608 with a single fastener 606. BecauseMLB 402 is compressed in the stackup that includes MLB 402, standoff 604and cowling 422, lateral motion of MLB 402 can be prevented at least byfrictional forces present in the stackup. In addition to providing amechanical linkage between the components in the stackup, fastener 606can form a ground path between the aforementioned components and rigidframe member 608. An electrically conductive portion 610 of standoff 604allows electricity to flow from MLB 402 to cowling 422, through fastener606 and into rigid frame member 608. For example, electricallyconductive pathway 612 shows how a component (not shown) disposed alonga top surface of MLB 402 can be grounded through standoff 604 andfastener 606. It should be noted that in some embodiments, all ofstandoff 604 can be conductive and in other embodiments, standoff 604can include a number of discrete conductive portions or pathways.Because the components can be efficiently grounded through standoff 604and fastener 606, additional grounding springs or grounding componentsneed not be utilized, thereby saving costs in components and assemblytime.

FIGS. 7A-7F show various carrier tab embodiments for improving amanufacturing and assembly process utilized with portable computingdevice 100. During assembly, various small components can be securedwithin housing 104 with precision in order to create a durable, stable,and functional product. To ensure alignment and positioning accuracyduring assembly, carrier tab 702 is set forth. Carrier tab 702 includesfastener opening 704, breakaway portion 706, breakaway holes 708, andsolder openings 710. Carrier tab 702 can be formed from metal. Forexample, carrier tab 702 can be formed from steel, aluminum, copper,and/or any other material that can be bonded with a flexible circuit. Inone specific embodiment, carrier tab 702 is formed from stainless steelthat is nickel plated.

Carrier tab 702 of FIG. 7A can be used when attaching a flexible circuitwithin housing 104. In some embodiments, the flexible circuit can beassociated with an antenna assembly. Carrier tab 702 can be bonded withthe flexible circuit to establish an additional handle or means to gripand place the flexible circuit. For example, a flexible circuit can havea pad that can be soldered to carrier tab 702. Solder openings 710 canbe utilized to assist in keeping the carrier tab 702 soldered to the padby allowing excess solder disposed between the pad and carrier tab 702to pass through solder openings 710 and bond to additional surfaces ofcarrier tab 702.

Breakaway portion 706 can act as a handle or grip means that is used tohold carrier tab 702 during an installation procedure. In someembodiments, carrier tab 702 can be maneuvered by a robotic arm thatgrips breakaway portion 706 during installation of carrier tab 702 andthe flexible circuit within housing 104. In this regard, carrier tab 702can be used to grip, move, and align the flexible circuit with respectto a portion of housing 104. The ability to align the flexible circuitis particularly useful when, for example, a mounting fastener needs tobe directed through a number of components such as the flexible circuit,a fastening feature of housing 104, and fastener opening 704 of carriertab 702. In one embodiment, a mounting fastener can be inserted throughfastener opening 704 and an opening in the flexible circuit in order tosecure the flexible circuit and carrier tab 702 against an interiorsurface of housing 104. Once the mounting fastener is securely fastenedand the flexible circuit is sufficiently affixed within housing 104,breakaway portion 706 can be broken off from carrier tab 702 alongbreakaway holes 708 by repeatedly bending breakaway portion 706 back andforth. Breakaway holes 708 help to ensure breakaway tab separates fromcarrier tab 702 along the breakaway holes by weakening that portion ofcarrier tab 702. Carrier tab 702 can take up less space inside ofhousing 104 once the breakaway portion 706 is discarded. Thereafter, theflexible circuit, remaining portion of carrier tab 702, and mountingfastener reside in the computing device, securely fixed in place.

FIGS. 7B and 7C show alternative embodiments of a carrier tab inaccordance with other embodiments. FIG. 7B shows carrier tab 712 that issimilar to carrier tab 702 such that fastener opening 714, breakawayportion 716 and solder openings 720 are similar to correspondingfeatures of carrier tab 702 respectively. Carrier tab 712 differs fromcarrier tab 702 in that it includes a single breakaway hole 718 insteadof the perforated breakaway holes 708. Breakaway hole 718 is a singleopening that is larger than any individual breakaway hole 708 of carriertab 702. In this way, breakaway hole 718 provides a different type ofperforation for breaking breakaway portion 716. Because more material isremoved this configuration may be easier to break away; however theincreased size of the opening may make a location of the breakaway pointless certain. FIG. 7C shows carrier tab 722 that is similar to carriertab 702. For example, fastener opening 724 and solder openings 726 aresimilar to corresponding features of carrier tab 702 respectively. FIG.7C also shows carrier tab 722 having two elongated breakaway holes 728for removing breakaway portion 730. Carrier tab 722 also includesopenings 728 that can be used to align carrier tab 722 with housing 104.For example, pins of a robotic arm can cooperate with openings 732 toalign carrier tab 722 within housing 104. In addition to openings 728,an alignment fiducial 734 can be disposed on the breakaway portion 730.Alignment fiducial 734 can also be an alignment feature that can be usedin aligning carrier tab 722 with housing 104. For example, alignmentfiducial 734 can be used in conjunction with a laser to help with properalignment of carrier tab 722 with respect to housing 104.

FIG. 7D shows a perspective view of carrier tab 702, and how a BreakingForce F can be used to separate breakaway portion 706 from carrier tab702. In some instances, it may be necessary to bend breakaway portion706 back and forth before breakaway portion 706 is dislodged fromcarrier tab 702. In other instances, it may be necessary to exert atwisting force on breakaway portion 706 before breakaway portion 706 isremoved from carrier tab 702. FIGS. 7E-7F show how carrier tab 712 canbe installed within portable computing device 100 and also how carriertab 712 fits within portable computing device 100 after removingbreakaway portion 706.

FIG. 7E shows carrier tab 712 disposed within an interior portion ofhousing 104 in accordance with some embodiments. Carrier tab 712 issoldered to flexible circuit 740. Flexible circuit 740 can be associatedwith components disposed within the housing 104. For example, flexiblecircuit 740 can communicate signals to LED 742, microphone 744, and/or acamera (not shown) associated with opening 750. A fastener 748 fastenscarrier tab 712 and flexible circuit 740 to a portion of interior framemember 750 of portable computing device 100. In this embodiment,fastener 748 is a screw and interior frame member 750 is a steelreinforcement frame. Interior frame member 750 can also be used tosupport a portion of button assembly 106 b. In this regard, flexiblecircuit 740 can also be used to communicate signals associated withbutton assembly 105 b. Another portion of flexible circuit 740 can alsobe secured within housing 104. For example, one end of flexible circuit740 can be fastened to mounting surface 752. FIG. 7F shows how,subsequent to fastening carrier tab 712 and flexible circuit 740 tointerior frame member 750, breakaway portion 716 can be removed fromcarrier tab 712. As previously discussed, removing breakaway portion 716can provide more interior space within housing 104 for other components.

FIGS. 8A-8C show an exemplary button assembly 105 b in accordance withsome embodiments. FIG. 8A shows a perspective view of internal andexternal portions of portable computing device 100. Disposed within aninternal portion of portable computing device 100 is a securing system802. Securing system 802 can include a bracket 804, a flexible circuit806, a switch 808, and a stiffener 810. Securing system 802 can be usedto secure switch 808 with housing 104 or other mounting surface suchthat switch 808 cooperates with button 812 to provide a switch buttonfunctionality for portable computing device 100.

Flexible circuit 806 can be a substantially planar substrate configuredto support and electrically couple various electrical components. Atleast one side of flexible circuit 806 can be configured to be coupledwith switch 808. Switch 808 can be mounted on one side of flexiblecircuit 806 while stiffener 810 is coupled to an opposing side offlexible circuit 806. In some embodiments, stiffener 810 is coupled toflexible circuit 806 with a heat-activated adhesive. Flexible circuit806 can electrically couple switch 808 to a processor (not shown) ofportable computing device 100.

Stiffener 810 can be formed of a conducting material such as stainlesssteel (SUS). For example, stiffener 810 can be formed from SUS Grade301. SUS is generally considered to be weldable by common fusion andresistance techniques. Accordingly, stiffener 810 can be welded tobracket 804. In this regard, the stiffener 810 can be used as anintermediate coupling device for securing flexible circuit 806 (andconsequently switch 808) to bracket 804. Bracket 804 can include one ormore alignment features or openings that can be used to fasten bracket804 to housing 104 or other mounting surface.

FIG. 8B shows a partial cross-sectional side view of a securing system,a button and a housing enclosure in accordance with one embodiment.Securing system 802 can be secured to the housing 104 or other mountingsurface so that switch 808 is aligned with button 812. Flexible circuit806 can be adhesively coupled or welded with (via stiffener 810) tobracket 804. Unfortunately, in certain embodiments, small components maynot have sufficient surface area to maintain a robust coupling between amounting surface, such as a bracket, and a flexible circuit. This can beof particular concern when the coupling is frequently subjected tonormal and/or force components as a part of normal operation of adevice. For example, flexible circuit 806 can undergo significantshearing force during actuation of switch 808 (by way of button 812) andcan cause the adhesive integrity between flexible circuit 806 andbracket 804 to be compromised. Consequently, a compromised couplingbetween flexible circuit 806 and bracket 804 can adversely affect thealignment between button 812 and switch 808. Poor alignment between thebutton 812 and switch 808 can cause a poor user experience when a useractuates button 812.

FIG. 8C shows a partial cross-sectional side view of a securing system,a button and a housing enclosure in accordance with another embodiment.In this embodiment, switch 808 can include an alignment feature 814 thatcan be sized and dimensioned to work in conjunction with an opening 816of bracket 804. In some aspects of the embodiment, alignment feature 814is an integrally formed portion of switch 808. For example, alignmentfeature 814 can take the form of a post or protrusion that is integrallyformed with switch 808. Alignment feature 814 can cooperate with opening816 to resist undesirable application of shearing forces upon switch808, particularly after prolonged use of switch 808. In this way anadhesive coupling can be substantially protected from an application ofshearing forces by the interaction between alignment feature 814 andopening 816. Furthermore, alignment feature 814 and opening 816 can alsoassist in aligning switch 808 with button 812 during an assemblyprocess.

FIG. 9A shows a front view of an exemplary portable computing device 100having a display assembly 902 and a button 904. Display assembly 902 canbe covered by protective cover 102 that provides a surface upon which auser can enter touch inputs in accordance with a user interfacedisplayed by display assembly 902. In some embodiments, protective cover102 can be formed from hardened glass while in other embodiments it canbe formed of other transparent materials such as, for example, plastic.Button 904 provides portable computing device 100 with a user interface.In some embodiments, button 904 can be utilized to activate portablecomputing device 100. Button 904 can be formed from plastic. In somecases, a plastic button 904 can be hard coated in order to provide aprotective coat. When actuated by a user, button 904 can provide a firmand stable tactile feel. The tactile feel can be created by interactionof button 904 with a flange and a mechanical switch disposed beneathbutton 904.

FIGS. 9B and 9C show cross-sectional side views of button 904 inaccordance with section line F-F and line G-G respectively. Button 904is depicted as being disposed within an opening in protective cover 102.In other embodiments, button 904 can be disposed within other enclosurecomponents of portable computing device 100. For example, the button 904can be disposed within an opening defined by a sidewall of housing 104.Button 904 includes an external surface having a concave shape such thata center of button 904 is recessed further into the opening of portablecomputing device 100 with respect to a periphery of button 904. Beneathbutton 904 is flange 906 that is operable to at least partially seal aninterface between protective cover 102 and button 904 and also toprovide resistance to actuation of button 904. Flange 906 can be formedfrom a flexible material such as polycarbonate. Flange 906 is supportedagainst button 904 by internal bracket 908 that extends around aperiphery of flange 906 and is coupled to both flange 906 and a bottomsurface of protective cover 102. The coupling can be accomplished in anumber of ways including by use of an adhesive. Internal bracket 908 isalso contoured so that it supports the varying shape of flange 906.Movement of button 904 is controlled in part by flange 906 as itactuates switch 910. In some embodiments, switch 910 can be a domeswitch that also contributes to an overall response provided duringactuation of button 904.

Flange 906 can have a varying cross-sectional thickness so that flange906 is substantially thicker along a periphery with respect to a centerof flange 906. In this configuration, flange 906 can allow the center ofbutton 904 to be recessed further than a periphery of button 904 therebyproviding a stable tactile response when button 904 is actuated.Accordingly, switch 910 can be positioned under the center of button 904to increase the likelihood that switch 910 will be actuated when button904 is pressed. By selectively thickening flange 906, a structuralintegrity of flange 906 can be enhanced so that flange 906 is lesssusceptible to cracking. Cracking can occur due to wear from multipleactuations of button 904. Furthermore, this configuration can alsoassist in preventing button 904 from protruding from the opening inprotective cover 102. In this regard, flange 906 positions button 904 ata desired height with respect to protective cover 102.

It should be noted that flange 906 can also be selectively thickened toleave space for components that are disposed near flange 906. Forexample, flange 906 can be thinner where components below flange 906 aretoo tall to accommodate an increased thickness. As depicted in FIGS. 9Aand 9B, flange 906 can have a thicker periphery in cross-section G-Gthan a periphery in cross-section F-F. The periphery thickness can bevaried in this way to accommodate components adjacent to peripheralportions of flange 906 (e.g., components associated with displayassembly 902).

FIG. 10A shows a side view of portable computing device 100. Buttonassembly 105 a is depicted as being disposed along a sidewall ofportable computing device 100. Button assembly 105 a can include a slideswitch 1002 that is installed within an opening 1004 disposed on asidewall of housing 104. A portion of slide switch 1002 protrudesthrough opening 1004. Slide switch 1002 can be used to provide portablecomputing device 100 with user interface functionality. For example,slide switch 1002 can be used as toggle ON/OFF switch. To actuate slideswitch 1002, a user can exert a force on the portion of slide switch1002 that extends through opening 1004, thereby causing slide switch1002 to move from a first position to a second position within opening1004 as indicated by the arrow.

FIGS. 10B-C show partial views of an internal portion of housing 104.Movement of slide switch 1002 is constrained by rails 1006, which definea vertical path along which slide switch 1002 can travel. Rails 1006 arecoupled to an internal frame member 1008. Internal frame member 1008 canbe disposed within housing 104. In some embodiments, internal framemember 1008 can be coupled to housing 104. For example, internal framemember 1008 can be coupled to an interior surface of housing 104 usingan adhesive, friction fit, fastening system, molding techniques orcombination thereof.

In one embodiment, rails 1006 can be coupled to internal frame member1008 by welding them together. For example, rail 1006 and internal framemember 1008 can be laser welded together. In another embodiment, rails1006 can be coupled to internal frame member 1008 by brazing. Rails 1006can be made from metal such as stainless steel or any other materialthat can be welded to internal frame member 1008. Internal frame member1008 can also be made from metal and is configured to be substantiallyrigid. Because rails 1006 are coupled with a substantially rigidinternal frame member 1008, a distance between rails 1006 stayssubstantially constant and is not subject to the type of deformationexperienced by a component coupled directly to housing 104. Thisstability can provide a user with a consistent tactical response whenthe user actuates slide switch 1002.

Furthermore, this configuration is preferred over one in which rails1006 are integrally formed along an inside surface of housing 104because formation of the rails within housing 104 can cause cosmeticproblems along an outside surface of housing 104. For example, theformation of rails using an injection molding operation typicallyresults in blemishes on the outside surface of housing 104. Slide switch1002 also includes protrusions 1010 facing away from opening 1004.Protrusions 1010 allow slide switch 1002 to engage an electrical switch(not shown) disposed adjacent to slide switch 1002. In this way, when auser maneuvers slide switch 1002 between positions, portable computingdevice 100 can execute an operation in response to a signal provided bythe electrical switch. For example, slide switch 1002 can provide ringercontrol functionality for portable computing device 100.

Additional modifications to the assembly process can be provided inorder to establish additional space within the computing device. Duringboth assembly and operation, the computing device should provide roominternally for various components to function properly. Functionalitycan be disrupted when components interfere with the operation of otherneighboring components inside the computing device.

FIG. 11A shows an internal view of an interior portion of portablecomputing device 100. Portable computing device 100 can include aflexible circuit 1102, a light emitting diode (LED) 1104, a microphone1106 and a camera 1108. Flexible circuit 1102 can include a first tail1102 a and a second tail 1102 b. LED 1104 can be coupled near one end offirst tail 1102 a and microphone 1106 can be coupled near one end ofsecond tail 1102 b. As described further below, first tail 1102 a andsecond tail 1102 b can be created by cutting flexible circuit 1102; thecut can result in gap 1100. Cutting flexible circuit 1102 to define oneor more tails, such as first tail 1102 a and second tail 1102 b, canprovide flexible circuit 1102 with an increased flexibility inmaneuvering and positioning. In this regard, first tail 1102 a andsecond tail 1102 b can extend to different positions within the interiorportion of portable computing device 100 without placing undo stress onflexible circuit 1102. This is particularly advantageous when first tail1102 a and second tail 1102 b extend to different planes.

LED 1104 can be configured to provide portable computing device 100 withan illumination device. Although embodiments herein describe an LEDconfigured to provide a camera flash, this embodiment is not limitingand it should be understood that an LED can also be used in anelectronic device for a variety of applications. For example, an LED canbe used to provide a visual indication, flashlight functionality and/orany other application where a light source is needed.

FIG. 11B shows a back view of portable computing device 100 inaccordance with some embodiments. Housing 104 of portable computingdevice 100 encloses LED 1104, microphone 1106, and camera 1108 withinthe portable computing device 100. Housing 104 can define an opening1116 for exposing LED 1104 to an outside environment. In this regard,light emitted from LED 1104 can be directed away from portable computingdevice 100. In use, LED 1104 can emit a flash of light substantiallyconcurrent with actuation of camera 1108 (i.e., when camera 1108 takes apicture). In some embodiments, LED 1104 is orientated such that theflash of light is emitted in substantially the same direction as thedirection camera 1108. Accordingly, LED 1104 can be disposed near camera1108 within portable computing device 100 as shown in FIGS. 11A and 11B.

In some cases, light emitted from LED 1104 can spread to undesirablelocations. For example, light from a camera flash can leak within theinterior of portable computing device 100 and spread to other portionsof portable computing device 100. The undesirable light leakage canadversely affect other operations or components of portable computingdevice 100. In some embodiments, the minimization of light leakage canbe realized by surrounding a portion of LED 1104 with a structure suchas a seal, adhesive, or shim. The structure can be a fixture or othercomponent coupled to an inner surface of housing 104 or to an innersurface of an interior frame member disposed within housing 104.

Referring back to FIG. 11A, a peripheral portion 1114 of first tail 1102a surrounding LED 1104 can be used as a surface for adhesively couplingthe first tail 1102 a to a mounting surface of a structure thatsurrounds LED 1104. The surface area of peripheral portion 1114 candepend on the size of LED 1104 and on the size of gap 1110. As describedin more detail below, the surface area of peripheral portion 1114 canhave an inverse relationship with gap 1110. In some embodiments, thesurface area of peripheral portion 1114 can be very minute, causingalignment between peripheral portion 1114 and the mounting surface to bedifficult due to a lack of surface area. Furthermore, in certainembodiments, peripheral portion 1114 does not have a sufficient surfacearea to maintain a robust adhesive coupling between the mounting surfaceand first tail 1102 a.

Coupling a small peripheral portion 1114 with the mounting surface canbe difficult and cumbersome, particularly when the coupling process isperformed by hand. In some embodiments, the mounting surface can bepositioned with respect to opening 1116 such that when peripheralportion 1114 is properly aligned and coupled to the mounting surface,the LED 1104 is also properly aligned with opening 1116. Consequently,any misalignment between peripheral portion 1114 and the mountingsurface can result in LED 1104 being misaligned with opening 1116. Amisalignment between LED 1104 and opening 1116 can result in anobstruction of light emitted from LED 1104 that is intended to passthrough opening 1116. In some embodiments, a larger peripheral portion1114 can be realized by cutting flexible circuit 1102 such that gap 1110is reduced. By reducing gap 1110, less surface area of flexible circuit1102 is cut away, providing more surface area to first tail 1102 a thatsurrounds LED 1104 (i.e., a larger peripheral portion 1114).

FIG. 12A shows an exemplary embodiment of flexible circuit 1102 that hasundergone a die cutting operation. As a result of the die cuttingoperation, flexible circuit 1102 includes a gap 1110 a having a lengthw1. Gap 1110 a can define in part a first tail 1102 a and a second tail1102 b of flexible circuit 1102. The die cutting operation can includemechanically cutting flexible circuit 1102 with a cutting tool. In someembodiments, the die cutting operation can include using a die as acutting guide when cutting flexible circuit 1102 with a cutting toolsuch as a blade. In other embodiments, a die having a cutting surfacecan be used as a cutting tool, similar to a cookie cutter. Whenperforming a mechanical cut with a cutting tool, the width of the cutcan be based on a width of a cutting surface of the cutting tool. Forexample, the width of the cut can be proportional to a width of acutting surface of a blade used to make the cut. In this regard, lengthw1 can depend on the cutting tool that was used in the die cuttingoperation. In some cases, a die cutting operation can result in a lengthw1 of about 0.5 mm.

As a consequence of gap 1110 a, LED 1104 is at a length, w2, from anedge of first tail 1102 a as shown in FIG. 12A. Length w2 can have aninverse relationship with length w1. In this regard, as gap 1110 aincreases (i.e., increasing length w1) the smaller first tail 1102 a(and/or second tail 1102 b) becomes. Furthermore, as gap 1110 adecreases, the larger first tail 1102 a (and/or second tail 1102 b)becomes. In some cases, the die cutting operation can result in a gap sobig that it results in first tail 1102 a having an insufficient amountof surface area for adhering first tail 1102 a to a mounting surface.

FIG. 12B shows an exemplary embodiment of flexible circuit 1102 that hasundergone a laser cutting operation. A laser cutting operation caninclude directing a high-powered laser at the material to be cut. Thelaser cutting operation can include any type of laser cutting including,but not limited to, vaporization cutting, fusion cutting, CO₂ basedlaser cutting, neodymium based laser cutting and/or neodymiumyttrium-aluminum-garnet based laser cutting. The laser used in a lasercutting operation can be focused on a very small spot on the material.For example, a laser can be focused on a spot having a diameter of about0.025 mm. Consequently, a laser cutting operation can provide a smallercut relative to a cut provided by a die cutting operation. Stillreferring to FIG. 12B, flexible circuit 1102 includes a gap 1110 bhaving a length w3. Length w3 can be substantially less than length w1.In some cases, length w3 can be on the order of ten times less thanlength w1. Hence, a length of gap 1110 b can be substantially smallerthan a length of gap 1110 a.

As a consequence of gap 1110 b, LED 1104 is at a length w4, from an edgeof first tail 1102 a as shown in FIG. 12B. First tail 1102 a in FIG. 12Bis larger relative to first tail 1102 a in FIG. 12A. As discussed above,a smaller gap can result in a bigger first tail 1102 a. In this regard,a length of first tail 1102 a has increased (relative to a correspondinglength of first tail 1102 a in FIG. 12A) with respect to length w4;consequently length w4 is greater than length w2. The laser cuttingoperation provides a means for cutting flexible circuit 1102 with asmaller cut resulting in first tail 1102 a having an increased surfacearea that surrounds LED 1104. The increased surface area can provide agreater tolerance in alignment and improve an adhesive coupling betweenfirst tail 1102 a and a mounting structure as described in FIGS.11A-11B.

FIG. 13 shows a block diagram representing a method for securing anumber of board-to-board connectors with a cowling. In a first step 1302at least one connector of a board-to-board connector is coupled with acommunication slot disposed on a PCB. At step 1304 a compressible layeris applied along a top surface of the board-to-board connector oppositethe connector. In some embodiments, the compressible layer can beadhered to the top surface of the board-to-board connector prior to theconnector being coupled with the communication slot. In someembodiments, the compressible layer can be a conductive foam pad. Atstep 1306 an inside surface of a metal cowling is compressed against thecompressible layer. This compression can be accomplished by fasteningthe cowling to the PCB. In this way, the connector can be preloaded bythe force transmitted through the compressible layer.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various aspects of the described embodiments can be implemented bysoftware, hardware or a combination of hardware and software. Thedescribed embodiments can also be embodied as computer readable code ona computer readable medium for controlling manufacturing operations oras computer readable code on a computer readable medium for controllinga manufacturing line. The computer readable medium is any data storagedevice that can store data which can thereafter be read by a computersystem. Examples of the computer readable medium include read-onlymemory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, andoptical data storage devices. The computer readable medium can also bedistributed over network-coupled computer systems so that the computerreadable code is stored and executed in a distributed fashion.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the describedembodiments. However, it will be apparent to one skilled in the art thatthe specific details are not required in order to practice the describedembodiments. Thus, the foregoing descriptions of specific embodimentsare presented for purposes of illustration and description. They are notintended to be exhaustive or to limit the described embodiments to theprecise forms disclosed. It will be apparent to one of ordinary skill inthe art that many modifications and variations are possible in view ofthe above teachings.

What is claimed is:
 1. A portable electronic device having a housingthat carries a first component and a second component, the portableelectronic device comprising: a retaining system independent of thehousing that secures a relative position of the first component withrespect to the second component such that a spacing between the firstcomponent and second component is substantially maintained when anexternal force is applied to the housing.
 2. The portable electronicdevice as recited in claim 1, wherein the first component is aboard-to-board connector and the second component is a communicationslot electrically coupled to the board-to-board connector, and theretaining system comprises a cowling having an inside surface thatexerts a force upon the board-to-board connector that secures therelative position of the board-to-board connector with respect to thecommunication slot.
 3. The portable electronic device as recited inclaim 2, wherein the inside surface of the cowling comprises a firststructural rib that exerts the force upon the board-to-board connectorby way of a compressible layer disposed over a portion of theboard-to-board connector.
 4. The portable electronic device as recitedin claim 3, wherein the first structural rib is stamped into the cowlingsuch that the first structural rib extends toward the compressiblelayer.
 5. The portable electronic device as recited in claim 3, furthercomprising a second structural rib, wherein the first structural rib andthe second structural rib are arranged cooperate to apply asubstantially even amount of force upon the board-to-board connector. 6.The portable electronic device as recited in claim 5, wherein the forcesexerted by the first structural rib and the second structural rib areexerted at opposite ends of the board-to-board connector.
 7. Theportable electronic device as recited in claim 2, wherein thecommunication slot is disposed on a printed circuit board (PCB), and theretaining system further comprises a standoff mounted to a first surfaceof the PCB and surrounding a fastener opening of the PCB, the standoffsetting a distance between the inside surface of the cowling and thefirst surface of the PCB, and wherein the standoff comprises anelectrically conductive pathway that electrically couples the cowlingwith the PCB.
 8. The portable electronic device as recited in claim 1,further comprising: a switch and a button partially disposed within anopening defined by an enclosure component of the portable electronicdevice; a switch; and a flange disposed between a portion of the buttonand a portion of the switch, the flange having a variable thickness suchthat a peripheral portion of the flange is thicker than a center portionof the flange thereby allowing a center portion of the button to berecessed further into the opening with respect to a peripheral portionof the button when a force is exerted on the button.
 9. The portableelectronic device as recited in claim 1, further comprising: a fasteningfeature disposed on a mounting surface; a C-shaped washer disposed alongan outside surface of the fastening feature, the C-shaped washer havinga plurality of diametrically opposed protrusions that exert a force onthe outside surface of the fastening feature; and an electroniccomponent coupled to the fastening feature such that a portion of theelectronic component engages and compresses the C-shaped washer.
 10. Amethod for securing a board-to-board connector within a communicationslot on a first surface of a printed circuit board (PCB), the methodcomprising: installing a connector of the board-to-board connectorwithin the communication slot of the PCB; attaching a compressible layerto a top surface of the board-to-board connector; and pressing an insidesurface of a cowling against the compressible layer to create a preloadthat biases the connector into the communication slot.
 11. The method asrecited in claim 10, further comprising: determining a loading patternexerted upon the cowling during a drop event; and reinforcing portionsof the cowling that are determined to experience a large amount ofdeformation as a result of a load exerted during the drop event.
 12. Themethod as recited in claim 11, wherein reinforcing comprises welding atleast one layer of metal to an inside surface of the cowling.
 13. Themethod as recited in claim 10, further comprising stamping a structuralrib into the cowling so that the structural rib is aligned with acentral portion of the communication slot when the cowling is coupled tothe PCB.
 14. The method as recited in claim 10, further comprisingstamping a structural rib into the cowling so that the structural rib isadjacent to a peripheral portion of the compressible layer and not indirect contact with the compressible layer when the cowling is coupledto the PCB.
 15. A cowling for securing a number of board-to-boardconnectors to a printed circuit board (PCB), the cowling comprising: ametal substrate comprising a flat contact region having a shape and sizein accordance with a compressible pad attached to an end of aboard-to-board connector; and a structural rib comprising an indentationin the metal substrate that protrudes from a bottom surface of the metalsubstrate, wherein a portion of the structural rib at least partiallysurrounds the flat contact region of the metal substrate and providesstructural reinforcement for the metal substrate.
 16. The cowling asrecited in claim 15, further comprising a metal plate coupled to thebottom surface of the metal substrate, the metal plate increasing arigidity of a portion of the metal substrate and being positioned totransmit a force to the board-to-board connector when the metalsubstrate is coupled to the PCB and when the board-to-board connector iscoupled with the PCB.
 17. The cowling as recited in claim 15, furthercomprising a plurality of metal plates welded to the bottom surface ofthe metal substrate in a stack, wherein the plurality of metal platesare formed from at least two different types of metal.
 18. The cowlingas recited in claim 15, wherein the structural rib is adjacent to atleast two sides of the board-to-board connector when the metal substrateis coupled to the PCB.
 19. The cowling as recited in claim 15, whereinthe structural rib surrounds a perimeter of the board-to-board connectorwhen the metal substrate is coupled to the PCB.
 20. The cowling asrecited in claim 15, wherein the cowling is formed from stainless steelsheet metal having a thickness of about 0.3 mm.